JP7254321B2 - Method for producing anti-allergen nonwoven fabric - Google Patents
Method for producing anti-allergen nonwoven fabric Download PDFInfo
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本発明は、主としてダニアレルゲンを低減化しうる抗アレルゲン不織布の製造方法に関するものである。 The present invention mainly relates to a method for producing an anti-allergen nonwoven fabric capable of reducing mite allergens.
従来より、カーテン、カーペット、ソファーや椅子の表皮材、テーブルクロス及び布団等の室内で用いる繊維製品に、ダニアレルゲンや花粉アレルゲン等のアレルゲンが付着して、居住者がアレルゲンを吸入しアレルギー疾患を発症することは知られている。このため、繊維製品に抗アレルゲン物質を付着させることにより、アレルギー疾患の発症を少なくすることが要求されている。特許文献１には、抗アレルゲン物質として、粘土鉱物からなるアレルゲン吸着剤を用いることが開示されている。 Conventionally, allergens such as mite allergens and pollen allergens adhere to textile products used indoors such as curtains, carpets, upholstery materials for sofas and chairs, tablecloths and futons, and residents inhale allergens and develop allergic diseases. known to occur. Therefore, it is required to reduce the occurrence of allergic diseases by adhering anti-allergen substances to textile products. Patent Document 1 discloses the use of an allergen adsorbent made of clay mineral as an anti-allergen substance.
本発明の課題は、特許文献１と同様に抗アレルゲン繊維製品を提供することにある。 An object of the present invention is to provide an anti-allergen textile product as in Patent Document 1.
本発明は、特許文献１記載の粘土鉱物とは異なる無機微粒子を抗アレルゲン物質として採用することにより、上記課題を解決したものである。すなわち、本発明は、構成繊維を集積してなる不織布本体に、結合剤を水中に乳化分散してなる結合剤エマルジョンと、酸化アルミニウム、二酸化珪素及び酸化亜鉛を含む無機微粒子を水中に分散させたスラリーとを混合してなる分散液を含浸して、該構成繊維相互間を該結合剤で結合すると共に、該無機微粒子を該不織布本体内部に該結合剤によって付着させることを特徴とする抗アレルゲン不織布の製造方法に関するものである。 The present invention solves the above problems by employing inorganic fine particles different from the clay mineral described in Patent Document 1 as an anti-allergen substance. That is, in the present invention, a nonwoven fabric body formed by accumulating constituent fibers, a binder emulsion obtained by emulsifying and dispersing a binder in water , and inorganic fine particles containing aluminum oxide, silicon dioxide and zinc oxide are dispersed in water. An anti-allergen characterized by impregnating a dispersion liquid obtained by mixing a slurry, binding the constituent fibers with the binding agent, and adhering the inorganic fine particles to the interior of the nonwoven fabric body with the binding agent. The present invention relates to a method for manufacturing nonwoven fabric.
無機微粒子を付着させる不織布本体としては、従来公知のスパンボンド不織布、ニードルパンチ不織布又はスパンレース不織布等が採用される。不織布本体がスパンボンド不織布の場合は、溶融紡糸した長繊維を構成繊維として集積した繊維ウェブに、熱エンボス加工を施し、構成繊維相互間を融着させて得ることができる。また、ニードルパンチ不織布の場合は、繊維ウェブにニードルパンチを施して、構成繊維相互間を絡合させて得ることができる。スパンレース不織布の場合は、繊維ウェブに高圧水流を施して、構成繊維相互間を絡合することにより得ることができる。また、ニードルパンチ、熱エンボス加工及び高圧水流処理を任意に組み合わせて不織布本体を得ることもできる。不織布本体の目付は任意であるが、タフトカーペット用一次基布として用いる場合は、一般的に５０～２００ｇ／ｍ2程度である。 A conventionally known spunbond nonwoven fabric, needle-punched nonwoven fabric, spunlaced nonwoven fabric, or the like is employed as the nonwoven fabric body to which the inorganic fine particles are attached. When the nonwoven fabric body is a spunbond nonwoven fabric, it can be obtained by heat-embossing a fibrous web in which melt-spun filaments are accumulated as constituent fibers to fuse the constituent fibers. A needle-punched nonwoven fabric can be obtained by subjecting a fibrous web to needle-punching to entangle the constituent fibers. A spunlaced nonwoven fabric can be obtained by subjecting a fibrous web to a high-pressure jet of water to entangle the constituent fibers. Also, the nonwoven fabric body can be obtained by arbitrarily combining needle punching, heat embossing and high-pressure water jet treatment. The basis weight of the nonwoven fabric body is arbitrary, but when used as a primary base fabric for a tufted carpet, it is generally about 50 to 200 g/m 2 .
不織布本体に付着させる無機微粒子は、酸化アルミニウム（Ａｌ2Ｏ3）、二酸化珪素（ＳｉＯ2）及び酸化亜鉛（ＺｎＯ）を含むものである。具体的には、無機微粒子が酸化アルミニウム、二酸化珪素及び酸化亜鉛の混合体となっている。また、無機微粒子が酸化アルミニウム、二酸化珪素及び酸化亜鉛の焼結体となっていてもよい。酸化アルミニウム、二酸化珪素及び酸化亜鉛の組成は任意であるが、一般的には、モル比で、酸化アルミニウム：二酸化珪素：酸化亜鉛＝１：１０～２０：１０～２０であるのが好ましい。無機微粒子の粒径は、均一な分散液を得る程度に微細であればよく、たとえば、多くの微粒子が１５μｍ以下となっているのが好ましく、５μｍ以下となっているのがより好ましい。分散液中における無機微粒子の含有量は、１～２０重量％程度である。 The inorganic fine particles adhered to the nonwoven fabric body contain aluminum oxide (Al 2 O 3 ), silicon dioxide (SiO 2 ) and zinc oxide (ZnO). Specifically, the inorganic fine particles are a mixture of aluminum oxide, silicon dioxide and zinc oxide. Also, the inorganic fine particles may be a sintered body of aluminum oxide, silicon dioxide and zinc oxide. Although the composition of aluminum oxide, silicon dioxide and zinc oxide is arbitrary, it is generally preferable that the molar ratio of aluminum oxide:silicon dioxide:zinc oxide is 1:10-20:10-20. The particle diameter of the inorganic fine particles is fine enough to obtain a uniform dispersion. For example, most of the fine particles are preferably 15 μm or less, more preferably 5 μm or less. The content of inorganic fine particles in the dispersion is about 1 to 20% by weight.
無機微粒子を不織布本体に付着させるには、結合剤を用いて付着させる。この結合剤としては、不織布本体の構成繊維相互間を結合するための結合剤と同一のものを採用する。同一の結合剤を採用すると、構成繊維相互間の結合と無機微粒子の付着とが同時に行えるからである。かかる結合剤としては、従来公知のものが採用されるが、アクリル酸エステル系結合剤又はＮＢＲやＳＢＲ等のゴム系結合剤等が用いられる。結合剤は、無機微粒子が分散している分散液中に含有させておき、無機微粒子と共に不織布本体に付与する。分散液中に結合剤を含有させる場合、結合剤の含有量は無機微粒子の含有量と同程度であるのが好ましい。結合剤の含有量が無機微粒子の含有量に比べて少なすぎると、無機微粒子を不織布本体に付着させにくくなる。また、結合剤の含有量が無機微粒子の含有量に比べて多すぎると、結合剤が無機微粒子を完全に被覆して、アレルゲンが無機微粒子と反応しにくくなる。 A binder is used to attach the inorganic fine particles to the nonwoven fabric body. As this binding agent, the same binding agent as that used to bind the constituent fibers of the nonwoven fabric body is employed. This is because when the same binder is used, the bonding between the constituent fibers and the adhesion of the inorganic fine particles can be performed at the same time. Conventionally known binders are used as such binders, and acrylic acid ester binders or rubber binders such as NBR and SBR are used. The binder is contained in the dispersion liquid in which the inorganic fine particles are dispersed, and is applied to the main body of the nonwoven fabric together with the inorganic fine particles. When a binder is contained in the dispersion liquid, the content of the binder is preferably about the same as the content of the inorganic fine particles. When the content of the binder is too small compared to the content of the inorganic fine particles, it becomes difficult to adhere the inorganic fine particles to the main body of the nonwoven fabric. Also, if the content of the binder is too large compared to the content of the inorganic fine particles, the binder completely coats the inorganic fine particles, making it difficult for the allergen to react with the inorganic fine particles.
分散液中には、さらに親水化剤及び／又は油剤を含有させておき、無機微粒子と共に不織布本体に付着させる。親水化剤は、無機微粒子が抗アレルゲン効果を奏するのに有効である。すなわち、親水化剤により水分が吸着され、水分の介在によってアレルゲンが無機微粒子と反応しやくなるのである。親水化剤としては、各種の界面活性剤を用いることができ、具体的には、ポリオキシアルキレンアルキルエーテル系ノニオン界面活性剤やスルホコハク酸系アニオン界面活性剤等が用いられる。分散液中の親水化剤の含有量は若干量であればよく、たとえば、１重量％以下でよい。 A hydrophilizing agent and/or an oil agent is further added to the dispersion liquid and adhered to the main body of the nonwoven fabric together with the inorganic fine particles. A hydrophilizing agent is effective for the inorganic fine particles to exhibit an anti-allergen effect. That is, water is adsorbed by the hydrophilizing agent, and the presence of water makes it easier for the allergen to react with the inorganic fine particles. Various surfactants can be used as the hydrophilizing agent. Specifically, polyoxyalkylene alkyl ether-based nonionic surfactants, sulfosuccinic acid-based anionic surfactants, and the like are used. The content of the hydrophilizing agent in the dispersion may be a small amount, for example, 1% by weight or less.
油剤としては、従来公知の繊維油剤を用いることができ、たとえば、シリコーンオイル系や脂肪酸エステル系の合成潤滑油を用いることができる。油剤を無機微粒子と共に繊維本体に付着させることにより、得られた抗アレルゲン不織布にタフティング機の針を貫通させやすくなるのである。すなわち、本発明に係る方法で得られた抗アレルゲン不織布を、タフトカーペット用一次基布の用途に用いる場合、タフティング機の針が抗アレルゲン不織布に通されパイル糸が埋め込まれるのであり、この際、油剤が抗アレルゲン不織布中に存在すると、無機微粒子があっても針を通しやすくなるのである。分散液中における油剤の含有量も、無機微粒子の含有量と同程度であるのが好ましい。油剤の含有量が無機微粒子の含有量に比べて少なすぎると、タフティング機の針が通しにくくなる。また、油剤の含有量が無機微粒子の含有量に比べて多すぎると、油剤の撥水性により、アレルゲンが無機微粒子と反応しにくくなる。 As the oil agent, a conventionally known textile oil agent can be used, and for example, a silicone oil-based or fatty acid ester-based synthetic lubricating oil can be used. By attaching the oil agent together with the inorganic fine particles to the fiber body, it becomes easier for the needle of the tufting machine to penetrate the obtained anti-allergen nonwoven fabric. That is, when the anti-allergen nonwoven fabric obtained by the method according to the present invention is used as a primary base fabric for a tufted carpet, the needles of a tufting machine are passed through the anti-allergen nonwoven fabric to embed the pile yarns. When the oil agent is present in the anti-allergen nonwoven fabric, the needle can easily be passed through even if there are inorganic fine particles. The content of the oil agent in the dispersion liquid is also preferably about the same as the content of the inorganic fine particles. If the content of the oil agent is too small compared to the content of the inorganic fine particles, it becomes difficult for the needle of the tufting machine to pass through. Also, if the content of the oil agent is too large compared to the content of the inorganic fine particles, the water repellency of the oil agent makes it difficult for the allergen to react with the inorganic fine particles.
結合剤は、上記したように、無機微粒子の分散液中に含有させて不織布本体に付着させる。さらに、本発明に係る方法で得られた抗アレルゲン不織布に、所望により、消臭剤、抗菌剤、防ダニ剤又は抗ウイルス剤等を、別途付着させてもよい。 As described above, the binder is contained in the dispersion liquid of the inorganic fine particles and adhered to the main body of the nonwoven fabric. Furthermore, if desired, a deodorant, an antibacterial agent, an anti-mite agent, an antiviral agent, or the like may be attached separately to the anti-allergen nonwoven fabric obtained by the method according to the present invention.
本発明に係る方法で得られた抗アレルゲン不織布は、種々の用途に用いられるが、上記したタフトカーペット用一次基布として用いるのが好ましい。本発明で用いる無機微粒子はダニアレルゲンに対する反応性が高く、ダニアレルゲンが堆積しやすい、カーペットの材料に適しているからである。なお、本発明で用いる無機微粒子がダニアレルゲンに対して高い反応性を有しているので、その他の各種繊維製品本体に付着して、抗アレルゲン繊維製品を得ることもできる。 The anti-allergen nonwoven fabric obtained by the method according to the present invention can be used for various purposes, but is preferably used as the primary base fabric for tufted carpets. This is because the inorganic fine particles used in the present invention have high reactivity with mite allergens and are suitable for carpet materials on which mite allergens tend to deposit. In addition, since the inorganic fine particles used in the present invention have high reactivity with mite allergens, they can be attached to other various textile products to obtain anti-allergen textile products.
本発明に係る方法で得られた抗アレルゲン不織布には、酸化アルミニウム、二酸化珪素及び酸化亜鉛を含む無機微粒子が付着している。そして、この無機微粒子はダニアレルゲン等のアレルゲンに対して高い反応性を有しているため、アレルゲンと反応して、それを不活性化させる。したがって、本発明に係る方法で得られた抗アレルゲン不織布が、たとえば、室内や自動車等のカーペットの材料として用いられていると、室内の居住者や自動車の使用者等がアレルギー疾患を発症しにくいという効果を奏する。また、本発明で用いる無機微粒子は、消臭効果、抗菌効果、抗カビ効果及び抗ウイルス効果等も、ある程度併有しているので、これらの効果も奏しうる。 Inorganic fine particles containing aluminum oxide, silicon dioxide and zinc oxide adhere to the anti-allergen nonwoven fabric obtained by the method according to the present invention. Since the inorganic fine particles are highly reactive to allergens such as mite allergens, they react with the allergens to inactivate them. Therefore, when the anti-allergen non-woven fabric obtained by the method according to the present invention is used as a material for carpets in rooms and automobiles, indoor residents and automobile users are less likely to develop allergic diseases. It has the effect of In addition, since the inorganic fine particles used in the present invention have a deodorizing effect, an antibacterial effect, an antifungal effect, an antiviral effect, etc. to some extent, these effects can also be exhibited.
実施例１
［不織布本体の準備］
カーボンブラックを含むポリエチレンテレフタレートを、スパンボンド法で溶融紡糸し、繊度約４．０デシテックスの長繊維群を集積して繊維ウェブを得た。この繊維ウェブに、パンチ密度６０回／ｃｍ2でニードルパンチを施し、長繊維相互間を絡合させて、目付１０５ｇ／ｍ2のパンチウェブを得た。このパンチウェブに、アクリル酸メチル及びアクリル酸エチルを主成分として共重合したアクリル酸エステル系結合剤を水中に乳化分散してなる結合剤エマルジョンを含浸し、１７０℃で乾燥及び熱処理して、長繊維相互間が絡合及び結合されてなる目付１１０ｇ／ｍ2の不織布本体を得た。
Example 1
[Preparation of nonwoven fabric body]
Polyethylene terephthalate containing carbon black was melt-spun by a spunbond method, and a group of long fibers having a fineness of about 4.0 decitex was accumulated to obtain a fiber web. This fiber web was subjected to needle punching at a punch density of 60 times/cm 2 to entangle the long fibers to obtain a punched web having a basis weight of 105 g/m 2 . This punched web is impregnated with a binder emulsion obtained by emulsifying and dispersing an acrylic ester-based binder in which methyl acrylate and ethyl acrylate are copolymerized as main components in water. A nonwoven fabric body having a basis weight of 110 g/m 2 was obtained by intertwining and bonding the fibers.
［分散液の準備］
酸化アルミニウム、二酸化珪素及び酸化亜鉛を含む無機微粒子を水中に分散させたスラリー（商品名「Ｍ－ＤＳ３３Ｂ」）と、上記した結合剤エマルジョンと、シリコーン系油剤とを準備し、重量比で、無機微粒子：結合剤：シリコーン系油剤＝１：１：１となる割合で混合し混合液を調製した後、ジオクチルスルホコハク酸ナトリウムを主成分とする親水化剤を、この混合液に対して０．２重量％添加して分散液を得た。
[Preparation of dispersion liquid]
Prepare a slurry (trade name “M-DS33B”) in which inorganic fine particles containing aluminum oxide, silicon dioxide and zinc oxide are dispersed in water, the binder emulsion described above, and a silicone-based oil. Fine particles: binder: silicone-based oil = 1:1:1. After preparing a mixed solution, a hydrophilizing agent containing sodium dioctyl sulfosuccinate as a main component is added to the mixed solution in an amount of 0.2. % by weight to obtain a dispersion.
［抗アレルゲン不織布の製造］
不織布本体に分散液を含浸した後、１７０℃で乾燥及び熱処理することにより、無機微粒子が結合剤によって付着されてなる目付１１９ｇ／ｍ2の抗アレルゲン不織布を得た。この抗アレルゲン不織布中には、無機微粒子３ｇ／ｍ2を含有するものであった。
[Production of anti-allergen nonwoven fabric]
After the nonwoven fabric body was impregnated with the dispersion, it was dried and heat-treated at 170° C. to obtain an anti-allergen nonwoven fabric having a basis weight of 119 g/m 2 with inorganic fine particles adhered by a binder. This anti-allergen nonwoven fabric contained 3 g/m 2 of inorganic fine particles.
実施例２
［不織布本体の準備］
実施例１と同一の方法で、目付１０５ｇ／ｍ2のパンチウェブを得た。このパンチウェブを不織布本体として準備した。
Example 2
[Preparation of nonwoven fabric body]
A punched web having a basis weight of 105 g/m 2 was obtained in the same manner as in Example 1. This punched web was provided as a nonwoven body.
［分散液の準備］
酸化アルミニウム、二酸化珪素及び酸化亜鉛を含む無機微粒子を水中に分散させたスラリー（商品名「Ｍ－ＤＳ３３Ｂ」）と、実施例１で用いた結合剤エマルジョンとを準備し、重量比で、無機微粒子：結合剤＝３：８となる割合で混合し、分散液を得た。
[Preparation of dispersion liquid]
A slurry of inorganic fine particles containing aluminum oxide, silicon dioxide, and zinc oxide dispersed in water (trade name “M-DS33B”) and the binder emulsion used in Example 1 were prepared, and the weight ratio of the inorganic fine particles was : Binder = 3:8 to obtain a dispersion.
［抗アレルゲン不織布の製造］
不織布本体に分散液を含浸した後、１７０℃で乾燥及び熱処理することにより、無機微粒子を結合剤によって付着した後、シリコーン系油剤を塗布して、目付１１９ｇ／ｍ2の抗アレルゲン不織布を得た。この抗アレルゲン不織布中には、無機微粒子３ｇ／ｍ2、結合剤８ｇ／ｍ2及びシリコーン系油剤３ｇ／ｍ2を含有するものであった。
[Production of anti-allergen nonwoven fabric]
After the nonwoven fabric body was impregnated with the dispersion, it was dried and heat-treated at 170°C to attach inorganic fine particles with a binder, and then coated with a silicone-based oil to obtain an anti-allergen nonwoven fabric with a basis weight of 119 g/m 2 . . This anti-allergen nonwoven fabric contained 3 g/m 2 of inorganic fine particles, 8 g/m 2 of binder and 3 g/m 2 of silicone oil.
［抗アレルゲン性の評価］
実施例１で用いた不織布本体及び実施例１で得られた抗アレルゲン不織布の各々から、７０ｍｍ×７０ｍｍの試験片を採取した。リン酸緩衝液にてダニアレルゲン（Ｄｅｒ２）濃度約７５ｎｇ／ｍｌに調製したアレルゲン溶液２ｍｌを、各試験片に浸み込ませた後、各ポリエチレン袋に密封した。このポリエチレン袋を４℃下で２４時間放置した後、アレルゲン溶液を搾り出して回収した。回収液をＥＬＩＳＡ用の溶媒組成に変換するため、変換液と等量混合した後、遠心処理を施して浮遊残渣を取り除き試験液とした。この試験液をＥＬＩＳＡ法によりアレルゲン濃度を測定した。その結果、不織布本体については１４１ｎｇであり、抗アレルゲン不織布については７ｎｇであった。このことから、実施例１で得られた抗アレルゲン不織布は、良好な抗ダニアレルゲン性を有することが分かる。また、実施例１に係る抗アレルゲン不織布をタフトカーペット用一次基布として用い、１９３０デシテックスのナイロン糸をタフト糸とし、１／１０ゲージで１０ステッチの条件でタフティングしたタフトカーペットを、前記と同様にしてアレルゲン濃度を測定したところ、２８ｎｇであった。したがって、実施例１に係る抗アレルゲン不織布をタフトカーペット用一次基布とした場合でも、カーペットに抗アレルゲン性を与えることができる。
[Evaluation of anti-allergenicity]
A test piece of 70 mm×70 mm was taken from each of the nonwoven fabric main body used in Example 1 and the anti-allergen nonwoven fabric obtained in Example 1. Each test piece was impregnated with 2 ml of an allergen solution prepared to a mite allergen (Der2) concentration of about 75 ng/ml with a phosphate buffer, and then sealed in a polyethylene bag. After leaving the polyethylene bag at 4° C. for 24 hours, the allergen solution was squeezed out and recovered. In order to convert the recovered liquid into a solvent composition for ELISA, an equal amount of the recovered liquid was mixed with the conversion liquid, followed by centrifugation to remove floating residues to obtain a test liquid. The allergen concentration of this test solution was measured by the ELISA method. As a result, it was 141 ng for the nonwoven fabric body and 7 ng for the anti-allergen nonwoven fabric. From this, it can be seen that the anti-allergen nonwoven fabric obtained in Example 1 has good anti-mite allergenicity. Further, a tufted carpet obtained by using the anti-allergen nonwoven fabric according to Example 1 as a primary base fabric for a tufted carpet, using 1930 decitex nylon yarn as a tufted yarn, and tufting under the condition of 10 stitches at 1/10 gauge, was prepared in the same manner as described above. The allergen concentration was measured as 28 ng. Therefore, even when the anti-allergen nonwoven fabric according to Example 1 is used as the primary base fabric for a tufted carpet, it is possible to impart anti-allergen properties to the carpet.
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Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2003010089A (en) | 2000-12-22 | 2003-01-14 | Sekisui Chem Co Ltd | Wiper sheet for carpet |
| JP2003113580A (en) | 2001-10-01 | 2003-04-18 | Toray Ind Inc | Nonwoven fabric compound material |
| JP2007039620A (en) | 2005-08-03 | 2007-02-15 | Daiwa Kagaku Kogyo Kk | Allergen-inactivating agent |
| JP2007145742A (en) | 2005-11-25 | 2007-06-14 | Matsushita Electric Works Ltd | Functional building material |
| JP3189215U (en) | 2013-12-18 | 2014-02-27 | 株式会社Ｈ＆Ｃ技術研究所 | Mite allergen suction brush |
| JP2017039290A (en) | 2015-08-21 | 2017-02-23 | 東洋紡株式会社 | Tufted carpet base fabric and tufted carpet |
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Patent Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2003010089A (en) | 2000-12-22 | 2003-01-14 | Sekisui Chem Co Ltd | Wiper sheet for carpet |
| JP2003113580A (en) | 2001-10-01 | 2003-04-18 | Toray Ind Inc | Nonwoven fabric compound material |
| JP2007039620A (en) | 2005-08-03 | 2007-02-15 | Daiwa Kagaku Kogyo Kk | Allergen-inactivating agent |
| JP2007145742A (en) | 2005-11-25 | 2007-06-14 | Matsushita Electric Works Ltd | Functional building material |
| JP3189215U (en) | 2013-12-18 | 2014-02-27 | 株式会社Ｈ＆Ｃ技術研究所 | Mite allergen suction brush |
| JP2017039290A (en) | 2015-08-21 | 2017-02-23 | 東洋紡株式会社 | Tufted carpet base fabric and tufted carpet |
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